Transmission Rebuild - 5th won't budge - JeepForum.com

 
LinkBack Thread Tools
post #1 of 15 Old 08-17-2008, 04:24 PM Thread Starter
twomanyjeeps
Registered User
1991 YJ Wrangler 
 
Join Date: Jan 2007
Location: ohio
Posts: 273
Transmission Rebuild - 5th won't budge

Rebuilding an AX-15, I'm to the part where you try to use a two-jaw puller to loosen up the fifth spline gear by placing the jaws behind the fifth counter gear. The darn thing just won't budge, this is a big puller, I've got a large breaker bar on the end and have so much pressure that the rod on the puller is starting to deform, and the gear is still just laughing at me. Has anybody attempted this before have any ideas on how to get this gear off. Any help would be greatly appreciated. And yes the snap ring is off.

twomanyjeeps is offline  
Sponsored Links
Advertisement
 
post #2 of 15 Old 08-17-2008, 05:00 PM
dave_dj1
Registered User
2001 TJ Wrangler 
 
Join Date: Jun 2006
Location: shushan, ny
Posts: 896
impact gun?

www.rok-freekz.com
Wheel it like ya stole it!
dave_dj1 is offline  
post #3 of 15 Old 08-17-2008, 05:22 PM
laybackman
Bikini Bridge Inspector
 
laybackman's Avatar
2010 JK Wrangler 
 
Join Date: Dec 2002
Location: Massachusetts
Posts: 6,948
Quote:
Originally Posted by twomanyjeeps View Post
Rebuilding an AX-15, I'm to the part where you try to use a two-jaw puller to loosen up the fifth spline gear by placing the jaws behind the fifth counter gear. The darn thing just won't budge, this is a big puller, I've got a large breaker bar on the end and have so much pressure that the rod on the puller is starting to deform, and the gear is still just laughing at me. Has anybody attempted this before have any ideas on how to get this gear off. Any help would be greatly appreciated. And yes the snap ring is off.
Did you remove the snap ring?
laybackman is offline  
post #4 of 15 Old 08-17-2008, 07:42 PM Thread Starter
twomanyjeeps
Registered User
1991 YJ Wrangler 
 
Join Date: Jan 2007
Location: ohio
Posts: 273
Yes, I removed the snap ring...I thought about using the impact gun, but like I said after using the breaker bar, I had so much force on the puller that the very tip of the rod on the puller was starting to deform. I'm afraid to put to much more force on it for fear of flying parts. I'm also not sure how gentle I should be with this. Or just get a bigger puller, but the one I have is just as big as what is portrayed in the manual.
twomanyjeeps is offline  
post #5 of 15 Old 08-17-2008, 08:14 PM
lah2420
Registered User
1995 YJ Wrangler 
 
Join Date: Mar 2006
Posts: 855
I got a puller set from Harbor Freight that has multiple sized bolts and thread counts. I bolted it into the two threaded holes in that pressed-on gear. Then I used an impact wrench on that. The part the wrench is working on pushes directly into the end of the shaft while pulling on the bolts. To me it kind of looks like a steering wheel puller. It seemed to work much easier than the one like you have. If I remember right, I might have had to use a breaker bar to loosen it the first time.

Here it is: http://www.harborfreight.com/cpi/cta...emnumber=37824
lah2420 is offline  
post #6 of 15 Old 08-17-2008, 08:57 PM Thread Starter
twomanyjeeps
Registered User
1991 YJ Wrangler 
 
Join Date: Jan 2007
Location: ohio
Posts: 273
Good deal, I'll try that as soon as I can...If I can pry even further, how did the rest of the rebuild go for you?
twomanyjeeps is offline  
post #7 of 15 Old 08-18-2008, 07:18 AM
laybackman
Bikini Bridge Inspector
 
laybackman's Avatar
2010 JK Wrangler 
 
Join Date: Dec 2002
Location: Massachusetts
Posts: 6,948
Quote:
Originally Posted by twomanyjeeps View Post
Rebuilding an AX-15, I'm to the part where you try to use a two-jaw puller to loosen up the fifth spline gear by placing the jaws behind the fifth counter gear. The darn thing just won't budge, this is a big puller, I've got a large breaker bar on the end and have so much pressure that the rod on the puller is starting to deform, and the gear is still just laughing at me. Has anybody attempted this before have any ideas on how to get this gear off. Any help would be greatly appreciated. And yes the snap ring is off.
Here's what my FSM says to do for a '95 AX-15 tranny. Grab these pics ASAP:
http://home.comcast.net/~laybackman/...ar_removal.htm
laybackman is offline  
post #8 of 15 Old 08-18-2008, 07:31 AM Thread Starter
twomanyjeeps
Registered User
1991 YJ Wrangler 
 
Join Date: Jan 2007
Location: ohio
Posts: 273
That is the same manual I'm using, the method in figure 31 isn't working, I like the other idea as there is two threaded holes on the spline gear. This way the force is applied directly to the gear instead of using the puller to move the whole assembly.
twomanyjeeps is offline  
post #9 of 15 Old 08-18-2008, 07:36 AM
laybackman
Bikini Bridge Inspector
 
laybackman's Avatar
2010 JK Wrangler 
 
Join Date: Dec 2002
Location: Massachusetts
Posts: 6,948
Quote:
Originally Posted by twomanyjeeps View Post
That is the same manual I'm using, the method in figure 31 isn't working, I like the other idea as there is two threaded holes on the spline gear. This way the force is applied directly to the gear instead of using the puller to move the whole assembly.
Do you mean FIG 32?? In any event, try tightening up the gear puller as much as possible then hitting the gear puller on the part where the socket goes with a BFH. Protect the end from mushrooming over with a socket and piece of board. The impact may pop it off.
laybackman is offline  
post #10 of 15 Old 08-18-2008, 07:45 AM
laybackman
Bikini Bridge Inspector
 
laybackman's Avatar
2010 JK Wrangler 
 
Join Date: Dec 2002
Location: Massachusetts
Posts: 6,948
There is a two piece bearing assembly used on the 5th gear. I wonder if it is frozen onto the shaft from wear/friction and the inside of the 5th gear? Unless you 'welded' the 2 piece bearing onto the shaft/gear, using the BFH to pop it loose should work.
laybackman is offline  
post #11 of 15 Old 08-18-2008, 04:05 PM
Cobra Jeep
Registered User
1993 YJ Wrangler 
 
Join Date: Aug 2005
Posts: 1,388
Yea when I rebuilt mine. I just threaded two bolts into the holes and used a harmonic balancer puller. Came right off. Dont know why yours is so tight.

'93 YJ 4.0L, AX-15, NP-231HD/SYE, 8.8in rear, OME 2.5 lift, home made front hub conversion, hydroboost. Warn M10000 winch. Currently building a stroker.

'79 Cherokee Chief, 401 MPFI fuel injection, T-18/D-20 and hydroboost. Otherwise stock.
Cobra Jeep is offline  
post #12 of 15 Old 08-18-2008, 05:41 PM
lah2420
Registered User
1995 YJ Wrangler 
 
Join Date: Mar 2006
Posts: 855
Quote:
Originally Posted by twomanyjeeps View Post
Good deal, I'll try that as soon as I can...If I can pry even further, how did the rest of the rebuild go for you?
My main problem was getting the bearing off so I could remove 1st gear. You do have to use 1st to pull that bearing. It also put a 25 ton press to the limits to remove and reinstall the bearing. Down side was that I broke some teeth on first doing it. I had a mechanic say to use a couple of pieces of flat aluminum plate to go between the gear and whatever you use to press the gear off. I didn't.
lah2420 is offline  
post #13 of 15 Old 08-18-2008, 07:36 PM Thread Starter
twomanyjeeps
Registered User
1991 YJ Wrangler 
 
Join Date: Jan 2007
Location: ohio
Posts: 273
Nothing has worked...Not the harmonic balance, not the tough love with the impact wrench and the hammer. I'm just going to take the guts to the shop and see if they can loosen up the 5th gear and the bearing infront of 1st.
twomanyjeeps is offline  
post #14 of 15 Old 08-19-2008, 08:55 AM Thread Starter
twomanyjeeps
Registered User
1991 YJ Wrangler 
 
Join Date: Jan 2007
Location: ohio
Posts: 273
Went to an automotive machine shop this morning and they were able to get it off using the harmonic balance puller type (the one I had from harbour frieght just wasn't cutting the mustard) but the gear fought every bit of the way. Looking at it now, there is several thousands of an interference fit between the shaft and the gear. I'm not sure which one is out of tolerance.
twomanyjeeps is offline  
post #15 of 15 Old 10-15-2013, 09:04 AM
waif69
Registered User
1987 YJ Wrangler 
 
Join Date: Mar 2010
Location: NJ
Posts: 141
I had the same problem this weekend, we actually broke the gear puller. After that we took it to the dealership and they got it pulled on Monday. Now to get to the rest of it. I don't want to take a day off work though.
waif69 is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.



Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
Transmission rebuild twomanyjeeps YJ Wrangler Technical Forum 3 09-13-2008 10:20 AM
ax5 transmission rebuild RobJ YJ Wrangler Technical Forum 1 02-15-2008 07:03 PM
97 Transmission Rebuild WTH?? TJRanger TJ Wrangler Technical Forum 16 10-09-2007 09:44 AM
Transmission rebuild? jeepfury YJ Wrangler Technical Forum 1 11-21-2005 01:14 AM
Transmission Rebuild Kit sequel YJ Wrangler Technical Forum 15 01-06-2005 02:39 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome